US11979101B2 - Sensor-free commutation method - Google Patents

Sensor-free commutation method Download PDF

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US11979101B2
US11979101B2 US17/600,503 US202017600503A US11979101B2 US 11979101 B2 US11979101 B2 US 11979101B2 US 202017600503 A US202017600503 A US 202017600503A US 11979101 B2 US11979101 B2 US 11979101B2
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commutation
phase
current
motor
rotor
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US20220173673A1 (en
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Thomas Kilian
Fabian Schneider
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Ebm Papst Mulfingen GmbH and Co KG
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Ebm Papst Mulfingen GmbH and Co KG
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P1/00—Arrangements for starting electric motors or dynamo-electric converters
    • H02P1/16—Arrangements for starting electric motors or dynamo-electric converters for starting dynamo-electric motors or dynamo-electric converters
    • H02P1/46—Arrangements for starting electric motors or dynamo-electric converters for starting dynamo-electric motors or dynamo-electric converters for starting an individual synchronous motor
    • H02P1/465—Arrangements for starting electric motors or dynamo-electric converters for starting dynamo-electric motors or dynamo-electric converters for starting an individual synchronous motor for starting an individual single-phase synchronous motor
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/14—Electronic commutators
    • H02P6/15—Controlling commutation time
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/14—Electronic commutators
    • H02P6/16—Circuit arrangements for detecting position
    • H02P6/18—Circuit arrangements for detecting position without separate position detecting elements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/20—Arrangements for starting
    • H02P6/22—Arrangements for starting in a selected direction of rotation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/26—Arrangements for controlling single phase motors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/28—Arrangements for controlling current

Definitions

  • the disclosure relates to a sensorless commutation method of a motor to a single-phase EC motor.
  • ECMs Single-phase electronically commutated motors
  • EP 2 086 104 A2 discloses an electronically commutated motor with an H-bridge and a rotor position sensor that generates an output signal.
  • the lower switch of the H-bridge is switched to a conductive state at a time t 2 ′.
  • the resulting electric circuit the electrical energy is converted into mechanical energy so that at a time t 3 ′ or t 1 , depending on the output signal, a commutation can occur where no current or only a small amount of it flows through the winding.
  • the time t 2 ′ is optimized through measurement and evaluation of the current flowing through the winding after the commutation.
  • the number of stator current pulses per rotor rotation of 360° el. is indicated, e.g. one-pulse, two-pulse, three-pulse, etc.
  • the number of phase windings is indicated in the stator, e.g. single-phase, two-phase, three-phase, etc.
  • EP 2 60 397 A1 discloses an embodiment where first, the position of the current ridge and the current amplitude at the maximum of the current ridge are determined. Then the minimum of the current in the region of the current saddle is determined and also possibly its amplitude. If a passage through the minimum has occurred and a value for the magnitude of the current that should trigger a commutation procedure has been detected, then the commutation procedure is triggered when the motor current has reached or exceeded this calculated value. In this case, depending on the requirements, this current value that triggers the commutation procedure can be mathematically manipulated. This occurs in such a way that the commutation occurs late during the start-up and is shifted further and further in the early direction as the rotation speed increases.
  • Commutation without a rotor position sensor has the advantage that the electronics of the motor can also be positioned at a distance from the motor.
  • components of the electronics can also be used for other tasks.
  • a microprocessor, used in the motor can also be used for regulating tasks, e.g. for a temperature regulation. This also permits a smaller embodiment of the motor, if necessary.
  • auxiliary torque is used. This is effective at the zero points.
  • this auxiliary torque could be mechanically generated by a spring. The spring is stressed in certain rotation positions and then releases its stored energy at the zero points.
  • the function of this auxiliary torque is primarily to turn the rotor so that at the start, it is not in a rotation position where the motor cannot generate any electromagnetic torque since otherwise, the motor would not be able to start.
  • asymmetries are used.
  • blowers or pumps have a preferred rotation direction.
  • An additional difficulty arises with blowers or pumps in that they can be “externally driven” by the transported medium, e.g. by air flows. Thus, it is not known whether this external drive will cause the rotor to rotate in the preferred direction or counter to it.
  • EP 1 596 495 A2 discloses detecting the rotation direction in such an EC motor with reluctance auxiliary torque based on the shape of the induced voltage. That is, based on the voltage that the rotating permanent-magnet rotor induces in a currentless phase winding.
  • a single-phase EC motor having one phase winding with two winding connections. It comprises: a current-regulating device in the phase winding between the winding connections. The current regulation regulates the winding current of the single-phase EC motor to a constant.
  • One fundamental idea of the disclosure includes the fact that the position sensorless commutation of a single-phase EC motor carried out through the direct use of a current regulation.
  • This current regulation e.g. a two-point regulation
  • the magnitude of the average output voltage of this (two-point) current regulator, that is present between the two winding connections of the motor is used to determine the commutation time, i.e. the change-over between the two commutation phases. This is carried out through simple comparison to a limit value. If the value falls below this limit value, then the change-over of the commutation phase is carried out.
  • the limit value here can be selected to be proportional to the amplitude of the constant current (ohmic voltage drop).
  • the commutation time corresponds to the time of the zero crossing of the synchronous internal voltage of the motor.
  • the winding current and synchronous internal voltage are in phase and an optimized torque is generated.
  • This corresponds to the commutation time of existing methods with direct detection of the synchronous internal voltage, but with the advantage that in the described method, it is not necessary to incorporate any current gaps.
  • the reversal of the current flow after a detected commutation time can not occur with maximal speed, but rather with a defined rate of change (e.g. through specification of a ramp function at the input of the current regulator). It is thus possible to achieve a further improvement with regard to the noise emission, particularly in the case of axial fans.
  • start-up of the motor from a stop is forced through a selective triggering of the change-over between the two commutation phases.
  • This can be specified, for example, by a fixed time interval after whose expiration a forced change-over of the commutation phase is carried out.
  • the rotor is thus set in motion and the further commutation is in turn carried out through feedback of the synchronous internal voltage to the output voltage of the (two-point) current regulator.
  • an evaluation of the average slope of the magnitude of the output voltage of the (two-point) current regulator during a commutation phase is used to determine the rotation direction of the motor. Due to an asymmetry in the geometry of the motor, the average slope of the magnitude of the synchronous internal voltage is dependent on the rotation direction of the rotor. This is reflected directly in the curve of the output voltage of the (two-point) current regulator. A slope of the magnitude that is positive on average during a commutation phase can thus be defined as a positive rotation direction. Conversely, a slope of the magnitude that is negative on average can be defined as a negative rotation direction. Consequently, when a positive desired rotation direction is needed, an unwanted negative actual rotation direction can be detected and reacted to in an appropriate way, for example, with braking and a subsequent restarting attempt.
  • the average output voltage of the (two-point) current regulator in this case is basically equivalent to the definition of a duty cycle.
  • the duty cycle/duty factor of the triggering instead of detecting the average voltage at the winding connections, it is advantageously possible to use the duty cycle/duty factor of the triggering (on-time relative to the cycle duration or stated more precisely, on-time relative to the on-time+off-time).
  • this can also be the PWM duty cycle of a triggering by pulse-width modulation (PWM).
  • FIG. 1 is a schematic view of an exemplary constant current regulation with the commutation phases
  • FIG. 2 is a schematic view of a function graph that depicts the magnitude of the average output voltage and the voltage limit value
  • FIG. 3 is a schematic view of a function graph that depicts the preset current at the current regulator with a defined rate of change;
  • FIG. 4 is a schematic view of a time curve of the synchronous internal voltage with a positive and negative rotation direction of a single-phase EC motor with an asymmetrical design of the stator teeth;
  • FIG. 5 is a schematic view of a time curve of the magnitude of the average output voltage with a positive and negative rotation direction of the EC motor
  • FIG. 6 is a schematic view of a block diagram of the commutation method
  • FIG. 7 is a schematic view of the flowchart: Start-up in a particular rotation direction;
  • FIG. 8 is a schematic view of the flowchart: Preparation for sensorless start-up;
  • FIG. 9 is a schematic view of the flowchart: Active braking of the EC motor.
  • FIG. 10 is a schematic view of a function graph that depicts the magnitude of the average output voltage and the voltage limit value during active braking;
  • FIG. 11 is a schematic view of a function graph that depicts the magnitude of the average output voltage during orientation with a rotor that is leveling off;
  • FIG. 12 is a schematic view of a a function graph that depicts the magnitude of the average output voltage during orientation with a rotor that is already correctly oriented.
  • the described method is essentially based on a bridge-triggering by f pulse-width modulation (PWM) in combination with a current regulator that constantly regulates the motor current by changing the PWM duty cycle. Based on the evaluation of the time curve of this PWM duty cycle, in addition to the detection of the commutation time, for other subtasks in the context of sensorless commutation, it is possible to achieve the commutation time.
  • PWM pulse-width modulation
  • it is possible to determine the magnitude of leveling-off motions of the rotor primarily in order to detect the progress of a rotor motion that is leveling off to a predetermined orientation position so as to shorten/minimize the necessary orientation time during start-up.
  • This method is enhanced by a parking function of the rotor.
  • the parking function moves the rotor into the desired orientation position when the rotation speed desired value is taken away (after motor operation) or when the supply voltage is applied (before motor operation) in order to enable the subsequent motor start-up with a minimal delay (due to the orientation of the rotor).
  • a sequence control or automatic operation control ensures the execution of the necessary steps during the start-up of the motor (braking, orientation with leveling-off detection, kick start in the preferred rotation direction or counter to it). Thus, it makes sure that the EC motor rotates in the desired rotation direction. If need be, independent start-up attempts are performed repeatedly.
  • FIG. 1 shows an exemplary commutation of a single-phase EC motor with a constant current regulation with the two successive commutation phases A and B.
  • the position sensorless commutation of the single-phase EC motor takes place through the use of a current regulation.
  • This current regulation e.g. a two-point regulation
  • power is supplied with a positive current flow.
  • the second commutation phase B that respectively follows commutation phase A, power is supplied with a negative current flow.
  • the current flow is essentially constant in this case and corresponds to the value î w and ⁇ î w , respectively.
  • the arrows and the dashed line indicate the commutation time where the commutation electronics, or stated more precisely the current regulator, produces a change-over between the commutation phases A and B.
  • FIG. 2 shows a function graph that depicts the magnitude of the average output voltage u w (t) of a two-point current regulator and the voltage limit value u WG .
  • the magnitude of the average output voltage of this (two-point) current regulator is used in this case to determine the necessary commutation time, the change-over between the two commutation phases A and B. This is carried out by a simple comparison to the depicted voltage limit value u WG .
  • the output voltage u w (t) falls at first and once it has fallen below the voltage limit value u WG , the change-over of the commutation phase A to the commutation phase B is carried out and so forth.
  • the voltage limit value u WG in this case can be chosen to be proportional to the amplitude of the constant current from FIG. 1 (ohmic voltage drop).
  • the commutation time in this case corresponds to the time of the zero passage of the synchronous internal voltage.
  • FIG. 3 shows a function graph that depicts the preset current at the current regulator with a defined rate of change in the time curve.
  • voltage limit value u WG By an intentionally different, i.e. deviating, voltage limit value u WG , it is possible to vary the commutation time and thus, for example, achieve an advantageous precommutation. This then compensates for the delayed reversal of the current flow in the motor winding at the commutation time that is caused by the winding inductance.
  • FIG. 3 it is clear that the respective reversal of the current flow after a detected commutation time does not occur erratically or at maximum speed (as shown in FIG. 1 ), but instead along a ramp function with a defined rate of change s w .
  • s w indicates the time derivative and thus the average rate of change. This is determined by the time differential of the current i w . Technically, this is achieved, for example, through specification of a ramp function at the input of the current regulator.
  • FIG. 6 shows an exemplary block diagram of the commutation method.
  • the ramp function is implemented via a ramp generation unit 10 by means of a desired value input “desired value”. It is specified as a “desired current value” at the input of the current regulator 11 .
  • the current regulator 11 transmits a corresponding “control variable” to the power electronics 12 that are connected to the EC motor 13 .
  • the power electronics 12 also include a current detection device 14 in order to detect the “actual current value.” This is sent to the current regulator 11 once again in order to adjust the “control variable” if need be.
  • the limit value is sent via the limit value detector 15 to a control logic circuit. with the commutation state at the input is sent to the ramp generation unit via an OR switch 16 and flip-flop 17 .
  • a rotation speed detector 18 and a rotation direction detector 19 are also provided. As is clear, the rotation direction detector 19 uses the magnitude of the time curve of the voltage and receives this from the slope detector 20 .
  • FIG. 4 shows the time curve of the synchronous internal voltage with a positive and negative rotation direction of a single-phase EC motor with an asymmetrical design of the stator teeth.
  • known asymmetrical concepts can be used where, for example, the air gap is not constant. Instead changes can be used in the circumference direction as a function of the tooth position of a winding tooth.
  • FIG. 7 shows a flowchart for explaining the start-up of a single-phase EC motor in a particular rotation direction.
  • the rotor is first oriented on a fixed starting position and then immediately started with the first sensorless commutation steps. No chronologically controlled acceleration with a fixed, predetermined rotating field ramp takes place.
  • the pattern of the first commutation steps in this case differs slightly depending on the desired rotation direction.
  • the first forced commutation takes place through inversion of a pseudo-Hall signal a substitute Hall signal based on which the commutation is performed, whereby the rotor is set in motion (motor start).
  • the first subsequent polarity change is already detected.
  • the next power supply pattern is activated by changing the pseudo-Hall level, whereupon the rotor continues its rotating motion.
  • the parameterization of the rotor position detection is finally changed to values for a normal operation and thus a switch is made into sensorless normal operation.
  • FIG. 8 shows a flowchart for explaining the preparation of a sensorless start-up, which at the end, is switched over into normal operation.
  • FIG. 9 shows a flowchart for explaining the active braking of the EC motor.
  • the flowchart includes the following sub-functions, establishment of the settings of the sensorless position detection that are optimized for braking and generation of a substitute Hall signal for the commutation for active braking.
  • FIG. 10 shows a function graph that depicts the magnitude of the average output voltage u w (t) and the associated voltage limit value for the commutation during active braking.
  • the applied average voltage is in phase opposition to the polarity of the synchronous internal voltage that is induced in the motor winding.
  • the current that the current regulator impresses into the winding is even achieved at an average voltage that is very low, comparatively speaking.
  • the average output voltage of the current regulator begins to increase. This increase above the limit value U wG is used for the commutation.
  • FIGS. 11 and 12 each show a function graph that depicts the magnitude of the average output voltage u w (t) during the orientation of the rotor with a constant winding current that is predetermined by the current regulator.
  • the orientation of the rotor and its virtually stopped state are basic requirements for the subsequent sensorless motor start (kick start).
  • FIG. 11 shows the curve of the average output voltage u w (t) with a rotor that was not previously in the orientation home position, with the leveling-off motion of the rotor reflected in the curve.
  • FIG. 12 shows the curve of the average output voltage u w (t) with a rotor that is already in the orientation home position.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Control Of Motors That Do Not Use Commutators (AREA)
US17/600,503 2019-05-27 2020-05-07 Sensor-free commutation method Active 2041-02-13 US11979101B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102019114073.0A DE102019114073A1 (de) 2019-05-27 2019-05-27 Sensorloses Kommutierungsverfahren
DE102019114073.0 2019-05-27
PCT/EP2020/062759 WO2020239385A1 (de) 2019-05-27 2020-05-07 Sensorloses kommutierungsverfahren

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US20220173673A1 US20220173673A1 (en) 2022-06-02
US11979101B2 true US11979101B2 (en) 2024-05-07

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US (1) US11979101B2 (de)
EP (1) EP3881426B1 (de)
CN (1) CN113557660B (de)
DE (2) DE102019114073A1 (de)
WO (1) WO2020239385A1 (de)

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EP1596495A2 (de) 2004-05-12 2005-11-16 ebm-papst St. Georgen GmbH & Co. KG Verfahren zum sensorlosen Betrieb eines elektronisch kommutierten Motors, und Motor zur Durchführung eines solchen Verfahrens
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EP3881426C0 (de) 2023-11-22
DE102019114073A1 (de) 2020-12-03
KR20220011612A (ko) 2022-01-28
US20220173673A1 (en) 2022-06-02
WO2020239385A1 (de) 2020-12-03
CN113557660A (zh) 2021-10-26
CN113557660B (zh) 2024-06-07
EP3881426B1 (de) 2023-11-22
EP3881426A1 (de) 2021-09-22
DE202019103001U1 (de) 2019-06-07

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